Composite and Nanocomposite Advanced Manufacturing Center (CNAM - PowerPoint PPT Presentation

Composite and Nanocomposite Advanced Manufacturing Center (CNAM Center) FY’ 15 Annual Report & Budget Presentation Research & Commercialization Council Meeting June 11, 2015 - 1:00 – 4:30 p.m. (CST) Sioux Falls, SD (Dr. David R. Salem) Center Director

Major Research Highlights #1  Developed CNAM process for producing fiber-reinforced thermoplastic composites comprising discontinuous fibers from recycled sources, and providing superior composite mechanical properties compared to conventional methods of incorporating discontinuous fibers in thermoplastic polymers  IP has been disclosed to SDSMT’s OSP (May 2015) for filing of a provisional patent  Needs further scale-up for continuous, integrated process

Major Research Highlights #2  Continental Structural Plastics (CSP) identified a semi- structural automotive component target application  This application requires continuous glass-fiber (GF) reinforced nylon sheets, which are then formed and “over-molded” to create a beam structure  Forming the nylon/GF tape is challenging and required development work using the CAPE Thermoplastic Impregnation Machine (CAPE TIM)  25 meters of GF/nylon sheet was produced by CNAM and provided to CSP for trials scheduled for June 13 th 2015

Collaboration CNAM Industrial Consortium Members  Industrial Advisory Board meetings: 8/2014, 1/2015 and 5/2015. Next: 8/2015  IAB Offices meetings: 7/2014, 12/2014, 3/2015, 4/2015  Technical reports issued to member companies every month  Annual Report (88 pages)issued to member companies, 8/2014  Semi-annual report (106 pages) issued to member companies, 5/2015  Materials supplied by SGL (fiber), Innegra (fiber/fabric), PolyOne (polymer)  Pilot Trials conducted at CSP (6/2014) and Raven Industries (5/2015) Examples of Other CNAM-Related Industrial Collaborations  Kaneka (recruited through CAMX booth): Phase 1: Exploration of core-shell toughening agents for composites  Teijin: Pre-pregging trial with highly-filled resin  Waterford Energy Solutions: Development of nanocomposite battery materials (involving10 faculty/researchers and 3 graduate students)  MarkForged: Phase 1: Development of thermoplastic pre-preg for 3D printing  SGL Group: Composites from nonwoven recycled fibers CNAM Academic Partners (SDSU and USD)  Biweekly SDSMT/SDSU/USD team Webex meetings to review and align activities  SDSU modeling (Hu) is focusing on material compositions developed at SDSMT  USD’s fiber surface modification work (Sereda) includes recycled carbon fibers being used in SDSMT’s composites process  SDSU’s NDE work (Du) is being applied to composites produced by SDSMT group

Grant Activity  Awards from industrial contracts, CNAM membership, State of South Dakota and Federal Government (DoD)  Grant submissions to DoD/DoTC and other agencies Fiscal Year Activity Pending Declined Awarded Previous Fiscal Years Total Number 3 3 4 Funding Amount 1,205,000 1,176,872 733,045 $ $ $ Total Fiscal Year 2015 Total Number 4 1 7 Funding Amount 8,136,946 318,828 861,582 $ $ $ Total Comprehensive Total $9,341,946 $1,495,700 $1,894,517

Center Funding  Membership fees from CNAM consortium companies ($92,500)  Contract research for Waterford Energy Solutions, SGL Group, Teijin, Kaneka, GreenTex, MarkForged and others  Federal grant from DoD/ARL: “Engineering the Mechanical Properties of Functionally Graded Syntactic Foams Incorporating Nanoparticle Reinforcements” Fiscal Year State Federal Industry/Other Total FY10 FY11 FY12 FY13 FY14 400,000 733,045 1,133,045 FY15 410,000 375,000 579,082 1,364,082 Total $810,000 $375,000 $1,312,127 $2,497,127

Job Creation  Multi-disciplinary, multi-institutional group working on CNAM-related or CNAM-generated projects include: ◦ 9 Faculty Members ◦ 5 Research Scientists and Research Engineers ◦ 1 Technician ◦ 14 Graduate Students ◦ 12 Undergraduate Students FTE Supported Undergraduate Graduate Researcher Total State Funding 2.53 3.75 2.13 8.41 University Funding 3.75 3.75 External Funding 1.0 1.5 5 7.5 Total 3.53 9 7.13 19.66

Sustainability  CNAM consortium members paid fees totaling $92,500 in FY2015. According to the contract, these fees double in FY16: thus ~$180,000 will be due from current members as of 9/1/15  3 full IAB meetings and 3 IAB officers meetings were held in FY15  Companies are engaged. Initial production trials took place at CSP and Raven Industries. New trial at CSP is scheduled for June 2015  National awareness of CNAM is increasing: CAMX exhibition booth and consortium network were the main promotional tools in FY15  Planning major publicity campaign in FY16: at August Annual Meeting, trade press editors will be invited to (non-proprietary) session to report CNAM activities in leading trade journals (Composites World, Plastics News etc.)….Coordinated by IAB officers, Director, and other IAB members with contacts and knowledge of the trade media  Once provisional patent on the CNAM process is filed, presentations at major technical and trade conferences are planned  Currently working on recruitment of targeted companies to join consortium  Brought in $580,000 of funding from CNAM-related industrial research contracts and $375,000 from CNAM-related federally funded contracts in FY15. Expected to be sustained or increased in 2016.

IP & Commercialization Activity  Full utility patent application for “Composite Materials with Magnetically Aligned Carbon Nanoparticles and Methods of Preparation” was filed 12/2014 (Hong, Peterson, Salem)  Provisional patent application on “Active Electrode Materials for High Capacity and High Performance Energy Systems” (Hong, Salem, Christensen, Yang) was filed 12/2014 and PCT was filed 4/15  Provisional patent application on “Micro-Channeled and Nano-Channeled Polymers for Structural, Thermal Insulation Composites” was filed 10/2014 (Salem and Schmid)  Patent disclosure was submitted to SDSMT’s Office of Sponsored Programs (5/2015) on “Discontinuous-Fiber Thermoplastic Composites with Engineered Properties” (Brady, Mannhalter, Salem) Frequency Disclosure/Under Provisional Patent(s) Review Patent(s) Filed Issued Previous 1 Fiscal Years Fiscal Year 1 2 2015 Total 1 3

Total FY’ 16 Budget Request Budget Classification Expenditures Personnel Existing Senior Personnel 120,363 Anticipated New Senior Personnel Post Doctoral Associates Graduate Students 39,004 Undergraduate students 37,700 Technicians/Clerical 27,017 Fringe Benefits 39,883 Additional Expenditures Equipment Supplies 13,813 Travel 3,000 Contractual Arrangements 116,220 Other 3,000 Total Direct Costs $400,000

Carry Over Request We request a short term carryover of the remaining FY15 funds to support the Center expenses (predominantly payroll) during the transition period for state funding to become accessible, including fund account setup by the contracts offices, which has historically taken until at least September 1. We have planned for this carryover so that we may continue to support research staff, graduate students and undergrad students through the summer months. Grant Amount Carryover JUN JUL AUG Expense Payroll & SDSMT – $286,615 $76,000 $25,333 $25,333 $25,333 supplies SDSU – $73,800 $21,711 $7,237 $7,237 $7,237 Payroll Payroll, USD – $39,585 $19,541 $10,000 $4,771 $4,770 supplies, equipment

Special Project Funding Request We request additional funding for a group of 4 projects with potential for rapid commercialization (projects 1- 3) or pioneering proof-of-concept (project 4) 1: Lightweight, Hollow-Particle Shear-Thickening Fluid s New shear-thickening fluid systems composed of hollow particles suspensions show an exceptionally strong shear thickening effect at much reduced density. The energy absorption and damping properties of these lightweight liquids will be investigated for application in flexible body armor, damping materials and sporting goods (skis, tennis rackets). Positive results will open up a rapid path to implementation/commercialization. 2: Micro and Nano-Channeled Thermal Insulation Materials We have produced micro- and nano-channeled polymer materials which indicate unusual dual properties of excellent thermal insulation and strong mechanical properties. Further demonstration of high-fraction nano- channeled materials with smaller channel diameters is required to determine their suitability for some important commercial applications. In addition to being used as rigid materials for food storage, construction and cryogenic vessels, there is strong potential for their application as flexible, breathable polymer films (e.g., new generation of Gortex-type materials) which would open up high-volume consumer markets.